Lid assembly for portable biochar kiln

ABSTRACT

A lid assembly for a portable biochar kiln and system is disclosed. An example of a lid assembly includes a cylindrical sidewall, a rim around the cylindrical sidewall, and a top portion having an opening formed therein. A removable stack is configured to fit over the opening formed in the top portion to direct exhaust from the portable biochar kiln. A gasket cover is interchangeable with the removable stack to fit over the opening formed in the top portion to form a substantially airtight seal over the opening formed in the top portion when a burn is complete in the portable biochar kiln to self-extinguish embers in the portable biochar kiln.

CROSS REFERENCE AND PRIORITY CLAIM TO RELATED APPLICATIONS

This application claims the priority filing date and benefit as acontinuation of U.S. patent application Ser. No. 16/149,789 for “GripperAssembly For Portable Biochar Kiln” filed Oct. 2, 2018, which is acontinuation-in-part of U.S. patent application Ser. No. 15/453,601 for“Portable Biochar Kiln” filed Mar. 8, 2017, which claims the prioritybenefit of U.S. Provisional Patent Application No. 62/317,573 filed Apr.3, 2016 for “Biochar Kiln.” This application claims the priority filingdate and benefit as a continuation-in-part of U.S. patent applicationSer. No. 14/378,357 for “Controlled Kiln and Manufacturing System ForBiochar Production”, filed Aug. 13, 2014, which is a national stageentry (371) of PCT Patent Application US2013/025999 filed Feb. 13, 2013,which claims the priority benefit of U.S. Provisional Patent ApplicationNo. 61/599,906 filed Feb. 16, 2012, U.S. Provisional Patent ApplicationNo. 61/599,910 filed Feb. 16, 2012, and Provisional Patent ApplicationNo. 61/604,469 filed on Feb. 28, 2012. Each of the above-referencedpatent applications is hereby incorporated by reference in its entiretyas though fully set forth herein.

BACKGROUND

Biochar is made from biomass (trees, agricultural waste, etc.) in anoxygen deprived, high temperature environment. Quality biochar has highpurity, absorptivity and cation exchange capacity. This can providesignificant benefits to several large markets including agriculture,pollution remediation, odor sequestration, separation of gases, oil andgas clean up, and more.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an example portable biochar kiln.

FIGS. 2-3 illustrate lifting and moving the example portable biocharkiln shown in FIG. 1.

FIGS. 4-5 illustrate removing a lid from the example portable biocharkiln.

FIGS. 6-7 are perspective views of an example lid of the portablebiochar kiln.

FIGS. 8-10 illustrate replacing the lid from the example portablebiochar kiln.

FIGS. 11-12 illustrate covering an opening in the lid for a stackassembly.

FIGS. 13-17 illustrate transporting the lid of the example portablebiochar kiln.

FIG. 18 illustrates assembling the lid and stack assembly on theportable biochar kiln.

DETAILED DESCRIPTION

A biochar kiln and system is disclosed, including construction of thekiln and various subsystems such as, but not limited to, ventilation,stack, control, insulation, and ember suppression. The kiln may beimplemented to produce biochar.

The biochar kiln is configured to support slow pyrolysis and canaccommodate a number of variables. Variables include, but are notlimited to, a “green” and/or dry feedstock, large and/or small pieces ofthe feedstock, various and multiple different species of the feedstock,and operation according to variable processing times. The biochar kilnis robust in that it may be operated under a number of variableoperating conditions, while still producing a consistent and highquality biochar product.

An example portable biochar kiln includes a body having a one-piecerolled wall, a curved floor attached to a sidewall. The example portablebiochar kiln also includes a ridge around an outside perimeter of thebody. The ridge is configured for engagement with a gripper attachmentfor heavy machinery to raise and lower the body. The example portablebiochar kiln also includes a removable lid. An edge is provided aroundan outside perimeter of the removable lid. The edge is configured forengagement with the same gripper attachment for heavy machinery to coverand uncover the lid on the body.

An example of a portable biochar kiln system includes a kiln body. Aridge is provided around an outside perimeter of the kiln body. Aremovable lid is provided to cover and uncover an opening in the top ofthe kiln body. An edge is provided around an outside perimeter of theremovable lid. The example portable biochar kiln system also includes agripper attachment for heavy machinery. The gripper attachment isconfigured for engagement with the ridge to raise and lower the kilnbody. The gripper attachment is also configured for engagement with theedge of the lid to cover and uncover the kiln body.

In an example, the kiln has a removable lid to permit easy loading offeedstock and unloading of biochar. The kiln may also have removablestacks and a stack hole sealing mechanism. In an example, the kiln istransportable and can travel to workstations, instead of making theworkstations travel to the kilns.

Before continuing, it is noted that as used herein, the terms “includes”and “including” mean, but is not limited to, “includes” or “including”and “includes at least” or “including at least.” The term “based on”means “based on” and “based at least in part on.”

FIG. 1 is a perspective view of an example biochar kiln 10. The biocharkiln 10 may include a main body portion 12 and a lid 14. The main bodyportion 12 is configured to receive a feedstock (not shown) by removingthe lid 14 and loading the feedstock before replacing the lid 14. In anexample, the biochar kiln further includes a base portion 16. The baseportion 16 may be configured such that it is raised off of the ground.This enables airflow under the main body portion 12. A ring 18 may alsobe implemented to lift the biochar kiln 10, e.g., using a loadertractor, forklift or other suitable machinery.

In an example, the kiln wall 20 may be made of a one-piece, rolled wall.Body welds, where needed (e.g., between the floor 222 and wall 20, andvarious ports), are made on curved surfaces to lower structural andthermal stress to those joints.

The floor 24 may also be a one-piece heavy gauge, high strength steel.The floor 24 may be downward elliptical-shaped (the shape being visiblein FIG. 1 and FIG. 5) to withstand heavy falling wood chunks duringfilling. The surface of the floor 24 is curved and has only one weldjoint along the perimeter where it joins with the wall 20. In an examplewhere the kiln floor is curved or substantially elliptical shaped andcannot balance the kiln, a multi-legged stand 16 with circular base 18may be attached (e.g., welded) to the kiln body 12, which travels withthe kiln body 12 as it is being transported.

Before continuing, it should be noted that the examples described aboveare provided for purposes of illustration, and are not intended to belimiting. Other devices and/or device configurations may be utilized tocarry out the operations described herein.

FIGS. 2-3 illustrate lifting and moving the example portable biocharkiln 10 shown in FIG. 1. The kiln body 12 may include a ridge. In anexample, the ridge 24 may be provided as a heavy gauge, rolled gripperangle iron is provided on the outside perimeter of the body, e.g.,around the walls 20. The ridge 24 may be substantially L-shaped, suchthat one leg of the L is mounted (e.g., welded or otherwise) to the wall20 and the other leg of the L provides a lip. However, otherconfigurations are also contemplated, such as a T-shape or other shaperidge that provides the lip around all or a portion of the perimeter ofthe wall 20.

This configuration enables structural durability, and the ridge 24provides an interface for grasping with a heavy machinery arm. In anexample, the heavy machinery may include a forklift. Other machinery(stationary or mobile) may also be provided to raise and lower the kiln,e.g., for transport.

In the example shown in FIGS. 2-3, a front-end loader 1 is implementedto raise and lower the kiln 10. The front-end loader 1 is shown as itmay be specially configured with a gripper attachment 26.

The gripper attachment 26 may be attached to the front-end or “wheel”loader 1 where a bucket or other tooling may typically be installed,e.g., at the ends of arms 2. The gripper attaches to the wheel loaderusing a JRB style quick attach interface which is standard or a factoryoption on many brands of wheel loaders.

Movement of the arms 2 enables raising, lowering, and tilting of thegripper attachment 26, and as such, anything grasped by the gripperattachment 26, such as the kiln 10.

In an example, the gripper attachment 26 is configured as a pincher.That is, the gripper attachment has two arms 28 a-b pivotally mounted tothe gripper attachment such that the arms 28 a-b can be opened (orloosened) and closed (or tightened).

In an example, a hydraulic rotor motor (not shown) is provided for thegripper attachment 26. The hydraulic rotor motor may be mounted to thegripper attachment 26, and wired into the cab of the front-end loader 1so that it can be controlled by the operator/driver. The hydraulic rotormotor may be provided to open and close the arms 28 a-b and/or rotatethe arms 28 a-b. As such, the hydraulic rotor motor may enable to thegripper attachment 26 to operate as a pincher. The hydraulic rotor motormay also enable a wheel loader to raise a kiln over a hopper and thendump its load (e.g., like a can of spaghetti into a saucepan). Thedumping operation takes less than a minute during which the kiln remainsattached to the wheel loader.

It is noted that the same hydraulic rotor motor may be implemented forboth rotation and pincher operation, or a separate motor(s) can beprovided.

During operation, the front-end loader 1 may approach the kiln 10 asshown in FIG. 2. The gripper attachment 26 may be raised off of theground at about the same height as the ridge 24. As the front-end loadermoves toward the kiln 10, a channel 30 formed in each of the arms 28 a-bmay be slid onto the ridge 24.

After positioning at the desired location, the arms 28 a-b of thegripper attachment 26 may be closed against the ridge 24 to secure thekiln body 12 within the gripper attachment. It is noted that thestructure of the ridge 24 may assist in preventing damage to the kilnwall 20, e.g., by providing additional support at the point(s) ofengagement between the arms 28 a-b and the kiln 10.

After engaging the arms 28 a-b with the ridge 24, the arms 2 of thefront-end loader 1 may be raised and/or tilted, depending on the desiredoperations, e.g., as shown in FIG. 3. As such, the front-end loader 1may be used to transport the kiln 10 to any desired location. By tiltingthe gripper attachment 26, contents can be emptied from the kiln 10.

The process described above can be reversed to lower and release thekiln 10. This will be readily understood by those having ordinary skillin the art after becoming familiar with the teachings herein, andtherefore a full description is not included.

FIGS. 4-5 illustrate removing a lid from the example portable biocharkiln. The lid 14 of the kiln 10 may include an edge 32. In an example,the edge 32 may be provided as a heavy gauge, rolled gripper angle ironis provided on the outside perimeter of the lid 14. The edge 32 may besubstantially L-shaped, such that one leg of the L is mounted (e.g.,welded or otherwise) to the lid 14 and the other leg of the L provides alip. However, other configurations are also contemplated, such as aT-shape or other shape ridge that provides the lip around all or aportion of the perimeter of the lid 14

This configuration enables structural durability, and the edge 32provides an interface for grasping the lid 14 with a heavy machineryarm. As noted above, the heavy machinery may include a forklift or othermachinery (stationary or mobile). In the example shown in FIGS. 4-5, thefront-end loader 1 is implemented to raise and lower and thus attach anddetach lid 14 from the kiln 10. The front-end loader 1 is shown as itmay be specially configured with the same gripper attachment 26described above for FIGS. 2-3.

During operation, the front-end loader 1 may approach the lid 14 of kiln10. The gripper attachment 26 may be raised off of the ground at aboutthe same height as the edge 32. As the front-end loader moves toward thekiln 10, a channel 30 formed in each of the arms 28 a-b of the gripperattachment 26 may be slid onto the edge 32.

After positioning at the desired location, the arms 28 a-b of thegripper attachment 26 may be closed against the edge 32 to secure thelid 14 within the gripper attachment. It is noted that the structure ofthe edge 32 may assist in preventing damage to the lid 14, e.g., byproviding additional support at the point(s) of engagement between thearms 28 a-b and the lid 14.

After engaging the arms 28 a-b with the edge 32, the arms 2 of thefront-end loader 1 may be raised and/or tilted, depending on the desiredoperations, e.g., as shown in FIG. 4. As such, the front-end loader 1may be used to cover and uncover the kiln 10, and to transport the lid14 to any desired location. FIG. 5 shows the inside of the kiln 10 afterthe lid has been removed. By tilting the gripper attachment 26, the ash,snow or debris can be removed from the lid 14.

FIGS. 6-7 are perspective views of an example lid 14 of the portablebiochar kiln 10, The lid 14 is shaped similar to the kiln floor 22. Inan example, the lid 14 is a one-piece elliptical or curved heavy gauge,high strength steel. The lid 14 may anneal with use (e.g., it getsstronger over time).

In an example, a diameter of the edge 32 of the lid forms a lip which isabout two inches greater than the outer perimeter of the kiln wall 20.As such the edge 32 of can sit on the kiln's top rim without falling in.In an example, the outer rim 34 of the lid 14 may seat within an innerperimeter of the kiln wall 20. In another example, the outer rim 34 maybe larger than the kiln wall 20 such that the outer rim 34 sits on topof the kiln wall 20. A gasket (not shown) may be provided between thelid 14 and the kiln wall 20.

In an example, a circular, downward flange is installed under the lid toblock condensed creosote from migrating to the lid's lip (it drips downonto the wood for reprocessing). If the creosote was allowed to migrateto the lip, it would make a hard, uneven interface with the seatingangle iron. The resulting gaps would result in difficult to manage airleaks.

FIGS. 8-10 illustrate replacing the lid from the example portablebiochar kiln. During operation, the front-end loader 1 carrying the lid14, may approach the kiln 10 as shown in FIG. 8. The gripper attachment26 may be raised off of the ground at about the same height or slightlyhigher than the top rim of the kiln 10. As the front-end loader movestoward the kiln 10.

After positioning at the desired location as shown in FIG. 9, the arms28 a-b of the gripper attachment 26 may lower the lid 14 onto the kiln10. After lower the lid 14, the gripper attachment 26 may release fromthe edge 32 to release the lid 14 on top of the kiln 10, as shown inFIG. 10.

FIGS. 11-12 illustrate covering an opening 38 in the lid 14 for a stackassembly (see, e.g., stack 15 in FIGS. 1 and 18). When the burn iscomplete, the stack 15 is removed from the lid 14 and a gasket cover 36is positioned to seal the opening 38 in the kiln lid 14. With the stackopening 38 and the bottom vent pipes sealed, the biochar embersself-extinguish due to lack of oxygen. The cover 36 may be positionedmanually by an operator, or using the gripper attachment 26 or othermachinery.

It is noted that a lighter duty gripper (or “mini-gripper”) may beprovided for low weight applications, such as lid and stack removal.FIGS. 13-17 illustrate transporting the lid 14 of the example portablebiochar kiln 10. FIG. 18 illustrates assembling the lid 14 and stackassembly 15 on the portable biochar kiln 10.

The mini-gripper 26′ permits use of smaller-weight machinery (e.g.,front-end loader 1′) which can result in cost savings (e.g., 60% to 70%over the cost of larger loaders 1). In an example, the mini-gripper 26′can be readily mounted to smaller machinery such as skid-steer-type ofequipment.

In FIG. 13, the front-end loader 1′ is shown as it may approach the lid14 (e.g., in this case the lid 14 is laying on the ground). The gripperattachment 26′ may be at about the same height as the edge 32 of the lid14. As the front-end loader moves toward the lid 14, a channel 30′formed in each of the arms 28 a′-b′ of the gripper attachment 26′ may beslid onto the edge 32.

After positioning at the desired location, the arms 28 a′-b′ of thegripper attachment 26′ may be closed against the edge 32 to secure thelid 14 within the gripper attachment 26′. After engaging the arms 28a′-b′ with the edge 32, the arms of the front-end loader 1′ may beraised, as shown in FIGS. 15-16. As such, the front-end loader 1 may beused to transport the lid 14 (as shown in FIG. 17) to any desiredlocation, such as to a kiln 10 shown in FIG. 18.

The gripper 26′ may also be operated as shown in FIG. 18 to add thestack 15 on top of the lid 14. The gripper 26′ may engage a ring 40 ofthe stack 15. Operation to engage ring 40 is similar to that alreadydescribed for engaging edge 32 of the lid 14. In an example, the stack15 may be assembled prior to positioning the lid 14 onto the kiln 10. Inanother example, the stack 15 may be assembled after positioning the lid14 onto the kiln 10.

The mini-gripper 42 also can be manufactured with less material, has asimplified arm actuator, and may have a limited rotor (e.g., forleveling only). Again, the mini-gripper 40 may include anindustry-standard attachment.

It is noted that the examples shown and described are provided forpurposes of illustration and are not intended to be limiting. Stillother examples are also contemplated.

The invention claimed is:
 1. A lid assembly for a portable biochar kiln,the lid assembly comprising: a cylindrical sidewall; a substantiallyL-shaped rim attached around the cylindrical sidewall by a plurality ofspacers, the rim having an outer diameter larger than an outer diameterof the cylindrical sidewall; a top portion having an opening formedtherein; a removable stack configured to fit over the opening formed inthe top portion to direct exhaust from the portable biochar kiln; and agasket cover interchangeable with the removable stack to fit over theopening formed in the top portion.
 2. The lid assembly of claim 1,wherein the stack is removed from the top portion and the gasket coveris positioned to seal the opening formed therein when a burn is completein the portable biochar kiln.
 3. The lid assembly of claim 2, whereinthe gasket cover forms a substantially airtight seal over the openingformed in the top portion.
 4. The lid assembly of claim 3, whereinembers in the portable biochar kiln self-extinguish after positioningthe gasket cover.
 5. The lid assembly of claim 1, further comprising anelongated handle portion of the gasket cover.
 6. The lid assembly ofclaim 5, wherein the handle portion of the gasket cover is manuallypositioned on the opening formed in the top portion.
 7. The lid assemblyof claim 5, wherein the handle portion of the gasket cover is positionedby machinery on the opening formed in the top portion.
 8. The lidassembly of claim 5, further comprising a mount for the handle portion,the mount attached to the rim.
 9. The lid assembly of claim 5, whereinthe handle portion moves from side to side in a mount to cover anduncover or partially uncover the opening formed in the top portion. 10.The lid assembly of claim 5, further comprising a first support memberconnected on a first end of the first support member to the cover and ona second end of the first support member to the handle portion.
 11. Thelid assembly of claim 10, further comprising a second support memberconnected on a first end of the second support member to the cover andon a second end of the second support member to the handle portion. 12.The lid assembly of claim 1, wherein the removable stack has a baseportion, a mid portion, and a top portion.
 13. The lid assembly of claim1, wherein the removable stack has an interior column supporting thebase portion, the mid portion, and top portion.
 14. The lid assembly ofclaim 1, wherein the rim is offset from the cylindrical sidewall. 15.The lid assembly of claim 1, wherein the rim has a top portion with awidth that is greater than a rim height and the cylindrical sidewall hasa width that is less than a sidewall height.
 16. The lid assembly ofclaim 1, wherein the stack is assembled prior to positioning the lidassembly onto the portable biochar kiln.
 17. The lid assembly of claim1, wherein the stack is assembled after positioning the lid assemblyonto the portable biochar kiln.
 18. A lid assembly for a portablebiochar kiln, comprising: a cylindrical sidewall; a substantiallyL-shaped rim attached in spaced apart relation to the cylindricalsidewall by a plurality of spacers, the rim having an outer diameterlarger than an outer diameter of the cylindrical sidewall; a top portionhaving an opening formed therein; a removable stack configured to fitover the opening formed in the top portion to direct exhaust from theportable biochar kiln, the removable stack has a base portion, a midportion, and a top portion; a gasket cover interchangeable with theremovable stack to fit over the opening formed in the top portion toform a substantially airtight seal over the opening formed in the topportion when a burn is complete in the portable biochar kiln toself-extinguish embers in the portable biochar kiln; a handle portion ofthe gasket cover; and a mount for the handle portion, the mount attachedto the rim.